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Publication numberUS2866206 A
Publication typeGrant
Publication dateDec 30, 1958
Filing dateAug 20, 1956
Priority dateAug 20, 1956
Publication numberUS 2866206 A, US 2866206A, US-A-2866206, US2866206 A, US2866206A
InventorsGebert Russell C
Original AssigneeLees & Sons Co James
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Pile fabric with resilient lining
US 2866206 A
Abstract  available in
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Claims  available in
Description  (OCR text may contain errors)

Dec. 30, 1958 R. c. GEBERT FILE FABRIC WITH RESILIENT LINING 2 Sheets-Sheet 1 Filed Aug. 20, 1956 mhLnobL/a Maid FIEL4.

PIE 5 Dec. 30, 1958 R. c. GEBERT PILE FABRIC WITH RESILIEINT mums 2 Sheets-Sheet 2 Filed Aug. 20, 1956 fuss 6% 6 2,866,206 1 FILE FABRIC WITH RESILIENT LINING Russell C. Gebert, Elkins Park, Pa., assignor to James lLees and Sons Company, Bridgeport, Pa., 2 corporation of Pennsylvania Application August 20, 1956, Serial No. 605,021 1 Claim. (Cl. 2-278) This invention relates to tufted textile floor coverings and more particularly to a tufted carpet in which a pad or underlay is formed integrally at the time of producing the fabric in the tufting machine.

The use of pads or underlays for floor coverings is in general well known. Ordinarily these are merely placed under the carpet. In other instances they may be secured to the carpet by means of an adhesive. In the tufting operation ditficulty has been experienced in providing an integral pad or underlay because the tufting needles tend to cut the underlay into strips so that without an adhesive, the backing tends to separate between the rows of tufts.

A primary object of the invention, therefore, is to provide a floor covering in which a resilient base or pad is utilized directly in the tufting machine so that no further steps are necessary.

A further object of the invention is to provide in a tufted carpet an integrally formed pad with suitable reinforcing means to prevent the pad from tearing.

Further objects will be apparent from the specification and drawings in which Fig. 1 is a perspective of a tufted carpet manufactured in accordance with the present invention,

Figs. 2-4 are warpwise sectional details of various embodiments of the invention,

- Fig. 5 is a sectional view as seen at 55 of 1,

Fig. 6 is a schematic view of a tufting machine capable of performing the present invention, and

Fig. 7 is a detail of the tufting operation.

The invention comprises essentially provision of a resilient pad material which is fed directly into the tufting machine in place of or in addition to a secondary fabric backing. In this way it is possible to tuft simultaneously a floor covering having a laminated base structure of both woven and non-woven material. The non-woven material may be felt padding, foam rubber, or any other suitable webbing which is of adequate resilience and capable of being fed into a carpet tufting machine. In a preferred embodiment the backing is utilized in conjunction with a fabric intended to materially strengthen the non-woven pad.

Referring now more particularly to the drawings, a carpet constructed in accordance with the present invention comprises a backing or base 10 which in the form of Figs. 1 and 5 is desirably foam rubber. The tufts 11 are woven through the foam rubber 10 and in addition a woven fabric material 12 which forms an upper sheet or covering for the rubber base 10. Loops 11 extend through the woven and non-woven materials and have stitches 13, 13 on the bottom of the fabric. The combination of fabric 11 and the foam rubber pad 10 is important in providing adequate control of the highly elastomeric, deformable base 10. It has been found that the stretching of such a rubber base frequently causes or induces cutting of the tufts so that the stitches 13 would tend to cut right through the rubber base. Fig. 3 illustrates a fabric in which a resilient base 15 may be used without the fabric, but unless adequate precautions are taken, thiswill be a much slower and less satisfactory expedient for obtaining good results. v

A hair felt pad 16 is shown in Fig. 2 as tufted directly without the use of a supplementary woven or textile nited States atent 2,866,206 Patented Dec. 30, 1958 ice backing. Here again precautions are recommended to prevent the pile from cutting or pulling out of the base fabric along the warpwise rows of stitching. Factors which must be considered in this connection among others are the thickness and density of the pad material.

In the production of a fabric in accordance with the invention, I feed the resilient padding material, regardless of its nature, through a conventional tufting machine such as shown in Fig. 6. This machine comprises a needle motion 20 having a crank shaft 21 and a vertically reciprocable needle bar 22 to which there are attached a plurality of needles 23, 23 by means of set screws 24, 24. The fabric, which may be if desired, a conventional woven backing material, is supplied to the tufting machine from a source 24 over rollers 25 and 26. From thence it is carried under a guide roller 27, feed pin roll 28, over the bed plates 29 of the machine, over take-up guide rollers 30 and 31 which are positioned on opposite sides of pin take-up roll 32. From thence the completed fabric passes over guide rollers 33 and 34 and is wound up on roll 36. The conventional loopers 37 are mounted on a rock shaft 38 and operated in the standard manner. The face yarn 39 is fed from a creel, not shown, through feed rolls 40 and 41 and guides 42 and 43.

The resilient backing material, which may be any one of the constructions shown in Figs. 2-5, is supplied from a beam or roll 44 and from thence over guides 45 and 46 where it meets with the fabric 12 at guide 27. In this way the resilient material is superimposed over the woven material 12 as they pass together across the bed 29 of the tuftingmachine. In the preferred form the woven textile material is supplied to the tufting machine underneath the pad, both of which are in the form of continuous webs or pellicles. One purpose in superimposing the resilient pad over the textile web is to provide the ease of control and absence of sticking which might otherwise occur as'the material is fed through the machine. However, depending upon the exact type and physical properties of the webs, this expedient may not be necessary, in which case, the stitches, rather than the pile projections, would be adjacent to the woven material.

It will thus be understood that I have provided an improved fabric and method for producing-same which has adequate strength and ability to withstand severe usage. The cost of manufacturing a carpet assembly with an integral resilient pad is thereby substantially References Cited in the file of this patent UNITED STATES PATENTS 1,855,916 Keeney Apr. 26, 1932 2,480,984 Van Issum Sept. 6, 1949 2,649,748 McCutchen Aug. 25, 1953 2,713,012 Harstein July 12, 1955 2,725,835 Mather Dec. 6, 1955 2,810,950 Rice Oct. 29, 1957 FOREIGN PATENTS 469,966 Great Britain Aug. 6, 1937

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US1855916 *Jul 2, 1930Apr 26, 1932Deltox Rug CompanyTufting attachment for sewing machines
US2480984 *May 12, 1947Sep 6, 1949Fabric Dev Company LtdManufacture of pile fabrics
US2649748 *Jan 17, 1952Aug 25, 1953 Method of sewing and tufting
US2713012 *Mar 13, 1952Jul 12, 1955Hartstein Fred WFloor rug
US2725835 *Apr 27, 1953Dec 6, 1955Robert I MatherComposite carpet and method of making same
US2810950 *Apr 17, 1956Oct 29, 1957Mohasco Ind IncTufted pile fabrics
GB469966A * Title not available
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US3176643 *Jun 26, 1963Apr 6, 1965Pepperell Mfg CompanyMethod of making a napped fabric
US3240176 *Jul 5, 1963Mar 15, 1966Morrison John RMethod for making simulated needlepoint embroidery
US3277547 *Dec 17, 1962Oct 11, 1966 Separable fastening element
US3348992 *Aug 13, 1963Oct 24, 1967Madison Res & Dev CorpTufted products
US3352739 *Nov 9, 1962Nov 14, 1967Reeves Bros IncFoam and fiber combination product and method of making same
US3385751 *Sep 18, 1963May 28, 1968Specialty ConvertersTufted pile carpet and manufacture thereof
US3394043 *Nov 7, 1966Jul 23, 1968Bigelow Sanford IncTufted carpet and non-woven backing fabric therefor
US3473495 *Oct 24, 1966Oct 21, 1969Nusbaum MortimerCarpet tile or floor covering and method of making the same
US3477763 *Aug 24, 1967Nov 11, 1969Otto GreichgauerBrush and method of producing the same
US4035533 *Jun 1, 1976Jul 12, 1977Champion International CorporationTufted carpet with meltable-film primary-backing component
US4140071 *Aug 9, 1977Feb 20, 1979E. I. Du Pont De Nemours And CompanyProcess for preparing tufted carpet
US4711190 *Aug 22, 1986Dec 8, 1987General Motors CorporationDecoratively stitched trim part and method
US7524778Nov 8, 2004Apr 28, 2009Henkel CorporationComposite sheet material
US7621228 *Jun 27, 2006Nov 24, 2009Pryce Kathy SHand stitching tool and method for using the same
US8465813 *Oct 23, 2007Jun 18, 2013Ten Cate Thiolon, B.V.Artificial lawn for artificial grass sports field
US20050064776 *Nov 8, 2004Mar 24, 2005Sobonya William A.Composite sheet material
US20060225632 *Jun 27, 2006Oct 12, 2006Pryce Kathy SHand stitching tool and method for using the same
US20100021660 *Oct 23, 2007Jan 28, 2010Geurt Bastiaan SlootwegArtificial lawn for artificial grass sports field
DE1560896B *Jun 20, 1962Mar 25, 1971Moelnlycke AbVerfahren zur Herstellung von steifen Kunststoffschichtstoffen
Classifications
U.S. Classification428/95, 112/80.1, 112/410
International ClassificationD05C17/02, D05C17/00
Cooperative ClassificationD05C17/02
European ClassificationD05C17/02